U.S. patent application number 13/646206 was filed with the patent office on 2013-09-12 for adjustable feedblock.
This patent application is currently assigned to Extrusion Dies Industries, LLC. The applicant listed for this patent is EXTRUSION DIES INDUSTRIES, LLC. Invention is credited to Michael K. Truscott, John A. Ulcej.
Application Number | 20130234359 13/646206 |
Document ID | / |
Family ID | 47073530 |
Filed Date | 2013-09-12 |
United States Patent
Application |
20130234359 |
Kind Code |
A1 |
Ulcej; John A. ; et
al. |
September 12, 2013 |
Adjustable Feedblock
Abstract
An adjustable feedblock configured for adjusting the thicknesses
of each layer of the juxtaposed extrudates forming a laminate. The
feedblock includes at least one pair of opposing combining planes
and at least one pair of opposing extrudate distribution blocks
that are removably disposed within the housing of the feedblock. As
such, the combining planes and the extrudate distribution blocks
partially define portions of the flow paths for the extrudates that
form the laminate within the housing of the feedblock. A method for
forming a laminate having juxtaposed layers of extrudates of
adjustable thicknesses is also disclosed.
Inventors: |
Ulcej; John A.; (Colfax,
WI) ; Truscott; Michael K.; (Chippewa Falls,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EXTRUSION DIES INDUSTRIES, LLC |
Chippewa Falls |
WI |
US |
|
|
Assignee: |
Extrusion Dies Industries,
LLC
Chippewa Falls
WI
|
Family ID: |
47073530 |
Appl. No.: |
13/646206 |
Filed: |
October 5, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61544126 |
Oct 6, 2011 |
|
|
|
Current U.S.
Class: |
264/171.1 ;
425/131.1 |
Current CPC
Class: |
B29C 48/495 20190201;
B29C 48/07 20190201; B29C 48/307 20190201; B29C 2948/92904
20190201; B29C 48/21 20190201; B29C 48/2556 20190201; B29C 2948/926
20190201; B29C 48/25686 20190201; B29C 48/92 20190201; B29C
2948/92647 20190201 |
Class at
Publication: |
264/171.1 ;
425/131.1 |
International
Class: |
B29C 47/06 20060101
B29C047/06 |
Claims
1. An adjustable feedblock, comprising a housing including a
primary inlet; one or more secondary inlets; and a laminate outlet;
one or more combining planes removably disposed within said
housing; one or more extrudate distribution blocks removably
disposed within said housing; a primary flow path within said
housing, said primary flow path extending between said primary
inlet and a primary outlet within said housing, wherein at least a
portion of said primary flow path proximate said primary outlet is
at least partially defined by a surface of said one or more
combining planes; one or more secondary flow paths within said
housing, wherein each one of said one or more secondary flow path
extends between at least one secondary inlet and at least one
secondary outlet within said housing, wherein at least a portion of
each one of said one or more secondary flow path proximate said
secondary outlet is at least partially defined by opposing edges of
one of said one or more combining planes and one of said one or
more extrudate distribution blocks; and a laminate flow path within
said housing, said laminate flow path extending between said
laminate outlet and proximately co-located primary outlet and said
at least one secondary outlet whereat said laminate is formed.
2. The feedblock of claim 1, wherein said primary outlet is at
least partially defined by an opening between opposing edges of two
or more combining planes; and said at least one secondary outlet is
at least partially defined by one of said one or more combining
planes and an opposing edges of said two or more extrudate
distribution blocks.
3. The feedblock of claim 1, wherein said one or more combining
planes are individually and independently adjustable.
4. The feedblock of claim 1, wherein said one or more combining
planes are configured to effectuate a thickness of extrudate
exiting said primary outlet; and a thickness of extrudate exiting
said one or more secondary outlets.
5. The feedblock of claim 1, wherein said one or more combining
planes are configured for operating in a free-floating mode
responsive to an equilibrium pressure exerted on said one or more
combining planes by mass flow rates of extrudates in said primary
flow path and in said one or more secondary flow paths.
6. The feedblock of claim 5, wherein an extent of said
responsiveness of said one or more combining planes to said
equilibrium pressure is individually and independently
adjustable.
7. The feedblock of claim 6, wherein said equilibrium pressure
exerted on said one or more combining planes determines a thickness
of extrudate exiting said primary outlet; and a thickness of
extrudate exiting said one or more secondary outlets.
8. The feedblock of claim 1, wherein said one or more combining
planes are set in a pre-determined fixed position.
9. The feedblock of claim 1, wherein said laminate comprises
juxtaposed layers of extrudate exiting two or more outlets selected
from the group consisting of said primary outlet and said one or
more secondary outlets.
10. The feedblock of claim 9, wherein said laminate is a two-layer
laminate comprising a layer of extrudate exiting two outlets
selected from the group consisting of said primary outlet and said
one or more secondary outlets.
11. The feedblock of claim 1, wherein at least a portion of said
one or more secondary flow paths within said one or more extrudate
distribution blocks is divergent.
12. The feedblock of claim 11, wherein at least a portion of said
one or more secondary flow paths within said one or more extrudate
distribution blocks is non-linear.
13. The feedblock of claim 1, wherein at least a portion of said
one or more secondary flow paths within said one or more extrudate
distribution blocks is non-linear.
14. The feedblock of claim 1, comprising at least two secondary
inlets; at least two secondary outlets; and at least two secondary
flow paths; wherein, each of said at least two secondary flow paths
extends between one of said at least two secondary inlets and one
of said at least two secondary outlets.
15. The feedblock of claim 1, wherein at least a portion of said
one or more secondary flow paths includes a concave shaped flow
path section formed in said one or more extrudate distribution
blocks.
16. The feedblock of claim 1, wherein each of said one or more
combining planes is provided with a keyed opening and an adjustment
mechanism disposed through said keyed opening.
17. A method for forming a laminate, comprising providing an
adjustable feedblock, comprising a housing including a primary
inlet; one or more secondary inlets; and a laminate outlet; one or
more combining planes removably disposed within said housing; one
or more extrudate distribution blocks removably disposed within
said housing; a primary flow path within said housing, said primary
flow path extending between said primary inlet and a primary outlet
within said housing, wherein at least a portion of said primary
flow path proximate said primary outlet is at least partially
defined by a surface of said one or more combining planes; one or
more secondary flow paths within said housing, wherein each one of
said one or more secondary flow path extends between at least one
secondary inlet and at least one secondary outlet within said
housing, wherein at least a portion of said one or more secondary
flow path proximate said secondary outlet is at least partially
defined by opposing edges of one of said one or more combining
planes and one of said one or more extrudate distribution blocks;
and a laminate flow path within said housing, said laminate flow
path extending between said laminate outlet and proximately
co-located primary outlet and said at least one secondary outlet
whereat said laminate is formed; introducing a flow of extrudate in
at least two of said primary inlet and said one or more secondary
inlets; forming said laminate within said feedblock, said laminate
comprising juxtaposed layers of said extrudate introduced in said
at least two of said primary inlet and said one or more secondary
inlets; and extruding said laminate through said laminate
outlet.
18. The method of claim 17, further comprising modulating mass flow
rates of extrudates to effectuate a thickness of each of said
juxtaposed layer of extrudate forming said laminate.
19. The method of claim 17, further comprising individually and
independently operating said one or more combining planes in a
free-floating mode responsive to an equilibrium pressure exerted on
said one or more combining planes by mass flow rates of extrudates
in one or more of said primary flow path and said one or more
secondary flow paths.
20. The method of claim 19, further comprising individually and
independently limiting an extent of said responsiveness of said one
or more combining planes.
21. The method of claim 20, further comprising effectuating a
thickness of each juxtaposed layer of extrudate responsive to said
equilibrium pressure.
22. The method of claim 17, further comprising effectuating a
thickness of each juxtaposed layer of extrudate by individually and
independently setting each of said one or more combining planes in
a pre-determined position.
23. The method of claim 22, further comprising positioning said one
or more combining planes to close either said primary flow path or
one of said one or more secondary flow paths to form a two-layer
laminate.
24. The feedblock of claim 17, wherein said feedblock comprises at
least two secondary inlets; at least two secondary outlets; and at
least two secondary flow paths; wherein, each of said at least two
secondary flow paths extends between one of said at least two
secondary inlets and one of said at least two secondary outlets;
and forming a three-layer laminate comprising a layer of extrudate
exiting said primary outlet sandwiched between juxtaposed layers of
extrudate exiting said at least two secondary outlets.
25. An adjustable feedblock, comprising a housing including a
primary inlet; one or more secondary inlets; and a laminate outlet;
one or more combining planes removably disposed within said
housing; one or more extrudate distribution blocks removably
disposed within said housing; a primary flow path within said
housing, said primary flow path extending between said primary
inlet and a primary outlet within said housing, wherein at least a
portion of said primary flow path proximate said primary outlet is
at least partially defined by a surface of said one or more
combining planes; one or more concave secondary flow paths within
said housing, wherein each one of said one or more concave
secondary flow path extends between at least one secondary inlet
and at least one secondary outlet within said housing, wherein at
least a portion of said concave secondary flow path proximate said
secondary outlet is at least partially defined by opposing edges of
one of said one or more combining planes and one of said one or
more extrudate distribution blocks; and a laminate flow path within
said housing, said laminate flow path extending between said
laminate outlet and proximately co-located primary outlet and said
at least one secondary outlet whereat said laminate is formed.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 61/544,126 filed Oct. 6, 2011, the
entirety of which is hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to a feedblock for forming a
laminate. In particular, the invention pertains to an adjustable
feedblock wherein the thicknesses of the extrudates forming the
laminate can be easily adjusted.
BACKGROUND
[0003] An extrusion die for manufacturing laminates having two or
more juxtaposed layers of extrudates includes a feedblock having
therein a corresponding number of separate flow paths for each
extrudate in the laminate. The thickness of each juxtaposed layer
of the extrudate is generally a function of the flow rate of the
extrudate and the size (e.g., the height) of the opening of the
corresponding flow path through which the extrudate exits.
Accordingly, for manufacturing laminates wherein the thicknesses of
the one or more layers of the extrudates are different, it becomes
necessary to dis-assemble the feedblock in order to remove and
exchange dies of different sizes in order to change the size of the
corresponding opening through which the extrudate exits. As will be
apparent to one skilled in the art, the actual (or exact) thickness
of each juxtaposed layer of the extrudate cannot be pre-determined
with any degree of certainty until after the die has been
re-assembled and operated. If the thickness of the one or more
layer is not as expected and/or is unacceptable, then the entire
process of dis-assembly, adjustment and re-assembly must be
repeated. As can be appreciated, this is an expensive and time
consuming proposition and prone to error. Even after the thickness
of the one or more layer of extrudate has been set as desired, a
change in the flow rate of an extrudate can affect the thickness of
the layer of that extrudate in the laminate. For example, if the
flow rate decreases, then the amount of extrudate exiting the flow
path will also decrease resulting in a thinner layer of that
extrudate. This may also affect the overall thickness of the
laminate and/or the thickness of the layers of the other extrudates
in the laminate.
[0004] Accordingly, there exists a need for an adjustable feedblock
wherein the thicknesses of the layers of the one or more extrudates
of a laminate can be manipulated without the necessity of
dis-assembling, adjusting and re-assembling the die.
SUMMARY
[0005] A non-limiting exemplary embodiment of the instant invention
is an adjustable feedblock for forming a laminate having multiple
layers of extrudates. The feedblock is structurally and
operationally configured for adjusting the thicknesses of each
layer of the extrudates forming the laminate. The feedblock
includes a housing having a primary inlet, one or more secondary
inlets, and a laminate outlet. One or more combining planes and one
or more extrudate distribution blocks are removably disposed within
the housing. A surface of the one or more combining planes define
at least a portion of a primary flow path extending between the
primary inlet and a primary outlet within the housing.
Additionally, the housing includes there within one or more
secondary flow paths, wherein each secondary flow path extends
between a secondary outlet within the housing and one or more
secondary inlets and wherein at least a portion of each secondary
flow path proximate the secondary outlet is defined by opposing
surfaces of one of the combining planes and one of the extrudate
distribution blocks. The laminate is formed at the approximate
location where the primary outlet and/or the one or more secondary
outlets are proximately co-located. The housing includes a laminate
flow path extending between the laminate outlet and the location
where the laminate is formed by juxtaposed layers of the extrudates
exiting the primary outlet and/or the one or more secondary
outlets. The primary outlet is at least partially defined by an
edge of the one or more combining planes, and each secondary outlet
is at least partially defined by an opening between the edge of one
of the combining planes and an opposing edge or surface of one of
the extrudate distribution blocks.
[0006] In accordance with a non-limiting exemplary embodiment of
the invention, each combining plane is individually and
independently adjustable. In another non-limiting example, each
combining plane is configured to effectuate the thicknesses of the
extrudates exiting the primary outlet and each secondary outlet. In
an embodiment of the invention, each combining plane is configured
for, and permitted to, operate in a free-floating mode responsive
to equilibrium pressures exerted thereon by the mass flow rates of
the extrudates in the primary flow path and/or in each secondary
flow path. Accordingly, the equilibrium pressure exerted on each
combining plane determines the thickness of the extrudate exiting
the primary outlet and the secondary outlet defined, at least
partially, by the combining plane. As such, the thicknesses of the
extrudates exiting the primary outlet and each one of the one or
more secondary outlets can be effectuated by modulating the mass
flow rates of the extrudates in the primary flow path and in each
one of the one or more secondary flow paths. In another embodiment
of the invention, the extent (or sensitivity) of the responsiveness
of each combining plane to the equilibrium pressures exerted
thereon is adjustable. In yet another embodiment of the invention,
each combining plane can be set in a pre-determined position.
Accordingly, the feedblock can be used for forming a multi-layer
laminate, and also for extruding a single layer of the extrudate
flowing through any one the primary and/or secondary flow paths. In
certain embodiments of the invention, the extrudate feedblock
includes a concave shaped surface at least partially defining a
concave-shaped flow path section in at least a portion of the
secondary flow path.
[0007] A method for forming a laminate, in accordance with a
non-limiting exemplary embodiment of the instant invention,
includes providing an adjustable feedblock according to embodiments
of the invention, introducing extrudates into the primary inlet and
into at least one secondary inlet of the adjustable feedblock. The
laminate is formed within the housing of the feedblock and is
extruded through the laminate outlet in the housing of the
feedblock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a cross-sectional view of an adjustable feedblock
in accordance with an embodiment of the invention;
[0009] FIG. 2 is a perspective view of the adjustable feedblock of
FIG. 1;
[0010] FIG. 3 is a perspective view of an extrudate distribution
block within the adjustable feedblock of FIG. 1;
[0011] FIG. 4 is a perspective view illustrating a portion of an
extrudate flow path within the extrudate distribution block of FIG.
3;
[0012] FIG. 5A is a side cross-sectional view of another embodiment
of an adjustable feedblock;
[0013] FIG. 5B is a side cross-sectional view of the feedblock of
FIG. 5A with one secondary inlet in fluid communication with two
secondary flow paths;
[0014] FIG. 5C is a side cross-sectional view of the feedblock of
FIG. 5B with one of the two secondary flow paths blocked;
[0015] FIG. 6A is a partial cross-sectional view of a portion of an
opposed pair of extrudate distribution blocks illustrating an
alternate embodiment of keyed openings in an opposed pair of
combining planes;
[0016] FIG. 6B is a perspective view of an extrudate distribution
block illustrating a combining plane with the keyed openings of
FIG. 6A; and
[0017] FIG. 6C is a perspective view illustrating a portion of an
extrudate flow path within the extrudate distribution block of FIG.
6B.
DETAILED DESCRIPTION
[0018] While multiple embodiments of the instant invention are
disclosed, alternate embodiments may become apparent to those
skilled in the art. The following describes only exemplary
embodiments of the invention with reference to the accompanying
drawings wherein like elements are designated by like numerals. It
should be clearly understood that there is no intent, implied or
otherwise, to limit the invention in any form or manner to that
described herein. As such, all alternatives are considered as
falling within the metes and bounds of the instant invention.
[0019] FIG. 1 is a cross-sectional view of adjustable feedblock 10
in accordance with a non-limiting exemplary embodiment of the
invention. Housing 12 of feedblock 10 includes primary inlet 14 and
two secondary inlets 16 and 18 through which extrudates are
introduced into feedblock 10. A laminate, formed within housing 12,
is extruded through laminate outlet 20. Feedblock 10 further
includes at least one pair of opposing combining planes 22 and 24
that are removably disposed within housing 12. Also removably
disposed within housing 12 of feedblock 10 is at least one pair of
extrudate distribution blocks 26 and 28. In an embodiment of the
invention, an opening between opposing edges 30 and 32 of the pair
of combining planes 22 and 24, respectively, at least partially
defines primary outlet 34 within housing 12 of feedblock 10.
Additionally, at least two openings, each between one of opposing
edges 30 and 32 and a surface of extrudate distribution blocks 26
and 28, at least partially defines at least two secondary outlets
36 and 38 within housing 12 of feedblock 10. In the non-limiting
exemplary embodiment illustrated in FIG. 1, secondary outlet 36 is
shown in a closed position and secondary outlet 38 is shown in a
partially open position.
[0020] Within housing 12, feedblock 10 includes primary flow path
40 extending between primary inlet 14 and primary outlet 34. In the
illustrated embodiment of the invention, at least a portion of
primary flow path 40 in proximity of primary outlet 34 is defined
by opposing surfaces of the pair of combining planes 22 and 24.
Additionally, housing 12 is illustrated having two secondary flow
paths 42 and 44, wherein each secondary flow path 42/44 extends
between respective secondary inlet 16/18 and corresponding
secondary outlet 36/38. As is apparent, the embodiment illustrated
in FIG. 1 includes two secondary inlets 16 and 18 in fluid
communication with respective secondary flow paths 42 and 44
extending between secondary inlets 16 and 18 and secondary outlets
36 and 38, respectively. It should be understood that it is not a
necessity that each secondary flow path include a correspondingly
dedicated secondary inlet. In some embodiments of adjustable
feedblock 10, housing 12 may include a unitary or a single
secondary inlet for introducing the extrudate into each secondary
flow path 42 and 44. In the illustrated embodiment of the
invention, at least a portion of each secondary flow path 42/44 in
the proximity of secondary outlet 36/38 is defined by a surface of
extrudate distribution block 26/28 and a surface of combining plane
22/24. For example, as shown in FIG. 1, portions 46 and 48 of
secondary flow paths 42 and 44 are respectively defined between the
surfaces of extrudate distribution block 26 and 28 and the surfaces
of combining planes 22 and 24. This is further described herein
below with reference to FIGS. 3 and 4.
[0021] While the embodiment of housing 12, as described herein with
reference to FIG. 1, includes two secondary inlets 16 and 18, two
secondary flow paths 42 and 44, one pair of opposing combining
planes 22 and 24, and one pair of extrudate distribution blocks 26
and 28, the instant invention is not to be construed as being
limited by the number or quantity of each one of these components
and/or their configurations and/or arrangements. Accordingly,
alternate embodiments of adjustable feedblock 10 can include less
than two or more than two of any one of secondary inlet, secondary
flow path, combining plane, and distribution block. For instance,
in a non-limiting exemplary embodiment, adjustable feedblock 10 can
include one secondary inlet, a pair of opposing combining planes,
and a pair of extrudate distribution blocks, wherein the one
secondary inlet is in fluid communication with each one of the two
secondary flow paths extending between the two previously described
secondary outlets and the one secondary inlet. In another
non-limiting exemplary embodiment, adjustable feedblock 10 can
include one secondary inlet, one secondary flow path, one combining
plane, and one extrudate distribution block, wherein the primary
outlet is at least partially defined by a portion of the one
combining plane, and the opening between opposing edges and/or
surfaces of the one combining plane and the one distribution block
at least partially define one secondary outlet, and the one
secondary flow path extends between the one secondary inlet and the
one secondary outlet. As will be apparent to one skilled in the
art, numerous combinations and/or arrangements of these components
of adjustable feedblock 10 are conceivable. Accordingly, all
variants of the described and/or illustrated embodiments are
considered as being within the metes and bounds of the instant
invention.
[0022] However, for the purposes of describing an embodiment of the
invention, the following often references two secondary inlets, two
secondary flow paths, two secondary outlets, an opposed pair of
combining planes, an opposed pair of extrudate distributions
blocks, etc. As stated, the number or quantity of each one of these
components and/or their configurations and/or arrangements should
not be construed as imposing any limitations on the described
and/or illustrated embodiments.
[0023] In the non-limiting exemplary embodiment shown in FIG. 1,
reference numeral 50 identifies an approximate location within
housing 12 where primary outlet 34 and secondary outlets 36 and 38
are proximately co-located. As such, reference numeral 50
identifies an approximate location within housing 12 where
extrudates exiting primary outlet 34 and each one of secondary
outlets 36 and 38 are juxtaposed to form a laminate. The laminate
so formed flows along flow path 52 and is extruded through laminate
outlet 20 in housing 12 of feedblock 10.
[0024] In accordance with an embodiment of the invention, each
combining plane 22 and 24 is individually and independently
adjustable to effectuate the extents of each opening defining
primary outlet 34 and each one of secondary outlets 36 and 38. As
will be apparent to one skilled in the art, movements of combining
planes 22 and 24 will therefore also effectuate the thicknesses of
extrudates exiting primary outlet 34 and each one of secondary
outlets 36 and 38.
[0025] In an embodiment of the invention, each combining plane 22
and 24 is configured for operating in a free-floating mode such
that either one or both combining planes 22 and 24 will move in
response to an equilibrium pressure exerted on each combining plane
22 and 24 by the mass flow rates of the extrudates in primary flow
path 40 and in each secondary flow path 42 and 44. As will be
apparent to one skilled in the art, a change in the mass flow rate
of extrudate in any one or more of primary flow path 40 and
secondary flow paths 42 and 44 will change the pressures exerted on
both combining planes 22 and 24 by the extrudates flowing in each
one of primary flow path 40 and secondary flow paths 42 and 44. For
example, an increase in the mass flow rate of extrudate in primary
flow path 40, with no change in the mass flow rates of extrudates
in both secondary flow paths 42 and 44, will increase the pressure
exerted on both combining planes 22 and 24 by the extrudate in
primary flow path 40. As such, the equilibrium pressures exerted on
each combining plane 22 and 24 will also change. In accordance with
this example, this change in the equilibrium pressures will both
increase the opening defining primary outlet 34 and decrease both
openings defining secondary outlets 36 and 38. As a result, the
thickness of the extrudate exiting primary outlet 34 will increase
while the thicknesses of the extrudates exiting each secondary
outlet 36 and 38 will decrease. Accordingly, when each combining
plane 22 and 24 is operating in a free-floating mode, a change in
the mass flow rates of extrudates in any one or more of primary
flow path 40 and secondary flow paths 42 and 44 will effectuate the
thicknesses of the extrudates exiting primary outlet 34 and each
secondary outlet 36 and 38 because a change in any one or the mass
flow rates will also change the equilibrium pressure exerted on
each combining plane 22 and 24 which, in turn, will effectuate the
openings defining primary outlet 34 and each one of secondary
outlets 36 and 38.
[0026] In an embodiment of the invention, each combining plane 22
and 24 respectively include keyed openings 54 and 56, or similar
configurations, for receiving a shaft or an extension of an
adjustment mechanism for individually and independently operating
and/or manipulating the responsiveness of each combining plane 22
and 24 to the equilibrium pressures exerted thereon, as described
in the foregoing. In an alternate embodiment of the invention, the
shaft of the adjustment mechanisms received in keyed openings 54
and 56 are configured for individually and independently setting
each combining plane 22 and 24 to a pre-determined position
reflective of the desired thicknesses of the extrudates exiting
primary outlet 34 and each secondary outlet 36 and 38 and forming
the laminate.
[0027] FIG. 2 is an external perspective view of the non-limiting
exemplary embodiment of feedblock 10 shown in FIG. 1. Feedblock 10
includes adjustment mechanisms 58 and 60 extending into housing 12.
In accordance with an embodiment of the invention, adjustment
mechanisms 58 and 60 respectively include an extension, e.g., a
shaft, which is compatible with and received in keyed openings 54
and 56 such that the shaft of each adjustment mechanism 58 and 60
can be individually and independently extended into respective
keyed openings 54 and 56, and thereafter rotated clockwise or
counter-clockwise for correspondingly moving combining planes 22
and 24 and thereby changing the openings defining primary outlet 34
and each secondary outlet 36 and 38. While adjustment mechanisms 58
and 60 are described as having rotational functions, alternate
embodiments, such as translational movements, for effectuating
movement of combining planes 22 and 24 for changing the openings
defining primary outlet 34 and each secondary outlet 36 and 38,
either individually or in combination, are considered as falling
within the metes and bounds of the instant invention.
[0028] As illustrated in FIG. 2, each adjustment mechanism 58 and
60 includes a corresponding gauge 62 and 64, or a similar
mechanism, configured for indicating the position of each combining
plane 22 and 24. In an alternate embodiment of the invention, each
gauge 62 and 64 is configured for indicating the extent of the
openings defining each secondary outlet 36 and 38 from which an
indication of the extent of the opening defining primary outlet 34
can be deduced. In another embodiment of the invention, each gauge
62 and 64 is configured for indicating both the positions of the
corresponding combining planes 22 and 24 and the extent of the
openings defining each secondary outlet 36 and 38. All alternative
embodiments for gauges 62 and 64 are considered as falling within
the metes and bounds of the instant invention.
[0029] In an embodiment of the invention, each combining plane 22
and 24 is configured for operating in a free-floating mode. In one
such embodiment, the extent to which each combining plane 22 and 24
responds to the equilibrium pressure exerted there onto is
adjustable. In other words, when operating in a free-floating mode,
the extent (or sensitivity) of the responsiveness of each combining
plane 22 and 24 to the equilibrium pressures (i.e., the mass flow
rates of the extrudates) can be changed. For example, during
certain processes with fluctuating mass flow rates of extrudates
the equilibrium pressures exerted on each combining plane 22 and 24
will also fluctuate. Accordingly, it may be desirable to restrict
(or dampen) the extent to which one or both combining planes 22 and
24 respond to the equilibrium pressures exerted thereon so that
there is less or no effect of the fluctuation in the one or more
mass flow rates (and pressures) on the thicknesses of the
extrudates exiting primary outlet 34 and each secondary outlet 36
and 38. To that end, in some embodiments of the invention,
feedblock 10 includes a counter-acting spring or other mechanism
(not shown) which can be manipulated to adjust the extent (or
sensitivity) of the responsiveness of each combining plane 22 and
24 to the equilibrium pressures exerted thereon. As will be
apparent to one skilled in the art, each combining plane 22 and 24
and/or each adjustment mechanism 58 and 60 can be configured for
incorporating such a sensitivity adjustment mechanism.
[0030] In an alternate embodiment of the invention, feedblock 10 is
configured such that the position of each combining plane 22 and 24
is individually and independently set to a pre-determined position
and, therefore, not responsive to any change in the equilibrium
pressures exerted thereon. Accordingly, the thicknesses of the
extrudates exiting primary outlet 34 and one or both secondary
outlet 36 and 38 is set at a pre-determined value.
[0031] In view of the foregoing disclosure describing non-limiting
exemplary embodiments of the instant invention, it will be apparent
to one skilled in the art that while feedblock 10 is configured for
forming a three-layer laminate at the approximate location
identified by reference numeral 50, it can just as well be used for
forming a two-layer laminate at that same location 50. For
instance, when combining planes 22 and 24 are operating in a
free-floating mode, the flow of extrudate in any one of primary
flow path 40 and secondary flow paths 42 and 44 can be stopped,
which, in turn, will result in the closure of the corresponding
outlet. For example, referring back to FIG. 1, it will be apparent
to one skilled in the art that termination of flow in secondary
flow path 42 will cause closure of secondary outlet 36 in response
to the equilibrium pressures exerted on combining planes 22 and 24,
respectively, by the mass flow rates of the extrudates in primary
flow path 40 and in secondary flow path 44. In accordance with this
example, the thicknesses of the extrudates exiting primary outlet
34 and secondary outlet 38 will be effectuated by the mass flow
rates of the extrudates in primary flow path 40 and in secondary
flow path 44. Similarly, termination of flow in primary flow path
40 will result in a closure of primary outlet 34, and the
thicknesses of the extrudates exiting each secondary outlet 36 and
38 will be effectuated by the mass flow rates of the extrudates in
each secondary flow path 42 and 44. Of course, as disclosed and
described in the foregoing, the extent (or sensitivity) of the
responsiveness of one or both combining planes 22 and 24 can be
adjusted. Furthermore, the thicknesses of the extrudates exiting
any one of primary outlet 34 and secondary outlets 36 and 38 can be
set to pre-determined values by appropriately setting the position
of one or both combining planes 22 and 24. As such, adjustments or
changes in the thicknesses of each layer forming the laminate can
be made without the need to stop operation of the die for
dis-assembling and re-assembling the feedblock. As will be apparent
to one skilled in the art, feedblock 10 can also be used for
extruding a single layer of any one of the extrudates flowing in
any one of primary flow path 40 and secondary flow paths 42 and
44.
[0032] In the non-limiting exemplary embodiment of feedblock 10
disclosed and described in the foregoing with reference to FIGS. 1
and 2, extrudate distribution blocks 26 and 28 are positioned in
opposing relationship within housing 12. As shown, extrudate
distribution blocks 26 and 28 are essentially identical, although
that is not required. In the following, the configuration of only
one extrusion distribution block, viz., extrudate distribution
block 28, is described with reference to FIGS. 3 and 4.
[0033] FIG. 3 is a perspective view of extrudate distribution block
28 including combining plane 24 in accordance with a non-limiting
exemplary embodiment of the instant invention. As illustrated,
extrudate distribution block 28 includes extrudate inlet block 70
abutting block 72. Extrudate inlet block 70 is configured for
accommodating removable combining plane 24 such that contoured
surface 74 of combining plane 24 is adjustable between a
spaced-apart opposed relationship with contoured surface 76 of
block 72 and a closed position. As illustrated, secondary outlet 38
is defined by an opening between edge 32 of combining plane 24 and
edge 78 (or at least a portion of contoured surface 76 in close
proximity of edge 78) of block 72. As will be apparent to one
skilled in the art, and in view of the foregoing description with
reference to FIGS. 1 and 2, a rotational movement of combining
plane 24 between an open and a closed position will change the size
of the opening defining secondary outlet 38. As illustrated, a
clockwise rotation of combining plane 24 will increase the size of
the opening defining secondary outlet 38 and a counter-clockwise
rotation of combining plane 24 will decrease the size of the
opening defining secondary outlet 38. As previously described, such
movement of combining plane 24 will effectuate not only the
thickness of the extrudate exiting secondary outlet 38, but will
also effectuate the thicknesses of the extrudates exiting primary
outlet 34 and secondary outlet 36.
[0034] As described in the foregoing with reference to FIG. 1, at
least a portion of primary flow path 40 in proximity of primary
outlet 34 is defined by opposing surfaces of the pair of combining
planes 22 and 24. As illustrated in FIG. 3, surface 80 of combining
plane 24 and a correspondingly opposed surface of combining plane
22 define the indicated portion of primary flow path 40 in
proximity of primary outlet 34.
[0035] Although not shown in FIG. 3, extrudate inlet block 70
includes an inlet and also includes flow path section 82
therewithin. Referring back to FIG. 1, it is seen that extrudate
introduced into secondary inlet 18 of feedblock 10 flows along
secondary flow path 44 within housing 12, and thereafter enters
into and flows within extrudate distribution block 28. As described
herein below with reference to FIG. 4, extrudate inlet block 70
includes flow path section 82, illustrated here as V-shaped, on at
least a portion of the surface of extrudate inlet block 70 opposite
a surface of abutting block 72. In other embodiments of the
invention, flow path section 82 is of a shape or configuration
different from the V-shape shown in FIG. 4. Accordingly, in a
non-limiting exemplary embodiment of extrudate distribution block
28, flow path section 82 can be U-shaped. As described herein below
with reference to FIG. 4, it should be understood that the
extrudate path of travel along flow path section 82 can be one of
or a combination of more than one shape.
[0036] FIG. 4 is a perspective view of extrudate inlet block 70
illustrating V-shaped flow path section 82 in accordance with a
non-limiting exemplary embodiment of the invention. The extrudate
flowing along flow path 44 enters extrudate inlet block 70 and
exits flow path 44 at outlet 84 in extrudate inlet block 70. While
outlet 84 in extrudate inlet block 70 is illustrated having a
circular cross-section, other embodiments may include outlet 84
having a cross-section of any geometric shape, including a square,
a rectangular, a triangular, a parallelogram, etc. For instance, in
a non-limiting embodiment of extrudate distribution block 28,
outlet 84 in extrudate inlet block 70 can be rectangular, for
example a slot, extending longitudinally between opposed sides of
extrudate inlet block 70. The slot can be substantially orthogonal
to the sides between which it extends, or it can be at an angle
relative the sides between which extends. It should be apparent
that while a unitary or a single outlet 84 is illustrated,
alternate embodiments of extrudate distribution block 28 can
include more than one outlet 84 in extrudate inlet block 70. For
instance, a non-limiting exemplary embodiment of extrudate
distribution block 28 can have two (or more) outlets 84 in
extrudate inlet block 70 forming a W-shaped flow path section 82.
Alternatively, outlet 84 can be configured as a manifold in
extrudate inlet block 70. Accordingly, all variants of the
described and/or illustrated embodiments are considered as being
within the metes and bounds of the instant invention.
[0037] As illustrated, apex 86 of flow path section 82 is located
at outlet 84 and in proximity of, and in fluid communication with,
secondary inlet 18. As will be apparent to one skilled in the art,
with block 72 in place abutting extrudate inlet block 70, the
extrudate exiting outlet 84 will flow along flow path section 82
and thereafter exit through secondary outlet 38 of extrudate
distribution block 28 as a sheet of extrudate. It should be
understood that upon exiting outlet 84, the extrudate path of
travel along flow path section 82 can be one of, or a combination
of, more than one shape. For instance, in a non-limiting embodiment
of extrudate distribution block 28, the path of travel from outlet
84 in extrudate inlet block 70 to secondary outlet 38, in other
words the path of extrudate travel along flow path section 82, can
be linear or curvilinear or any alternate shape or any combination
thereof. Accordingly, in a non-limiting exemplary embodiment of
extrudate distribution block 28, the path traveled by the extrudate
after exiting outlet 84 in extrudate inlet block 70 is concave. In
certain embodiments of extrudate distribution block 28, the shape
of the path of extrudate travel is at least partially defined by
extrudate inlet block 70 or abutting opposed block 72 or both.
[0038] Referring back to FIGS. 1-4, primary inlet 14 and secondary
inlets 16 and 18 are illustrated as being located on the same side
or wall of housing 12 opposite the side or wall of housing 12 on
which laminate outlet 20 is located. Also, primary flow path 40
extending between primary inlet 14 and primary outlet 34 is
illustrated as being substantially straight. Similarly, at least
some portions of secondary flow paths 42 and 44 extending from
their respective secondary inlets 16 and 18 through at least a
portion of their respective extrudate distribution blocks 26 and 28
are illustrated as being substantially straight. However, as will
be apparent to one skilled in the art, such locations for the
inlets and such linear configurations of the flow path are not
strictly required. In a non-limiting exemplary embodiment, one or
both secondary inlets 16 and 18 are located on one or more walls or
sides of feedblock 12 other than the walls or sides on which
primary inlet 14 and laminate outlet 20 are located. For instance,
if the wall or side of feedblock 12 on which primary inlet 14 is
located is considered to be a "back wall" and the wall or side of
feedblock 12 on which laminate outlet 20 is located is considered
to be a "front wall", then one or both secondary inlets 16 and 18
can be located on either one of the two "side walls" or on both
"side walls" extending between the "front wall" and the "back wall"
of feedblock 12. In a non-limiting exemplary embodiment, both
secondary inlets 16 and 18 are located on the same "side wall".
Alternatively, secondary inlets 16 and 18 are located on opposite
"side walls" of feedblock 12. In certain embodiments, one of the
two secondary inlets 16 and 18 is located on the same "back wall"
as primary inlet 14 and the other secondary inlet is located on one
of the two "side walls" of feedblock 12. In another embodiment,
primary inlet 14 is located on one of the two "side walls" and
either one or both secondary inlets 16 and 18 are located on the
"back wall" and/or on one or both "side walls" of feedblock 12. In
view thereof; it will be apparent to one skilled in the art that
one or more of primary inlet 14 and secondary inlets 16 and 18 can
be located on any wall of feedblock 12. It should be also apparent
that other embodiments can include one or more of primary inlet 14
and secondary inlets 16 and 18 on the "top wall" and/or on the
"bottom wall" of feedblock 12. Still further alternative locations
for one or more of primary inlet 14 and secondary inlets 16 and 18
will become apparent to one skilled in the art. All variants of the
described and/or illustrated embodiments are considered as being
within the metes and bounds of the invention.
[0039] Additionally, there is no requirement that each secondary
flow path have a corresponding and dedicated secondary inlet. Some
embodiments of adjustable feedblock 10 may include one secondary
inlet in fluid communication with one or more secondary flow paths.
Other embodiments of adjustable feedblock 10 may include one or
more secondary inlets in fluid communication with one secondary
flow path. Certain embodiments of adjustable feedblock 10 may
include one or more secondary inlets in fluid communication with
one or more secondary flow paths. One such embodiment has been
described in the foregoing with reference to FIG. 1. As can be
seen, several combinations and arrangements for the extrudate
inlets and/or the extrudate flow paths in the primary and/or the
secondary flow paths are possible as alternate embodiments. All
such variants of the described and/or illustrated embodiments are
considered as being within the metes and bounds of the instant
invention.
[0040] In view of the foregoing, it will be apparent to one skilled
in the art that one or more of primary flow path 40 and secondary
flow paths 42 and 44 do not always have to be straight flow paths.
Also, the flow paths do not have to be substantially horizontal as
illustrated. For instance, in a non-limiting exemplary embodiment
one or more of primary flow path 40 and secondary flow paths 42 and
44 twist and turn as they extend between their respective inlets
and outlets. In other embodiments, the one or more flow paths can
be angled relative to one another and/or angled relative to one or
more of laminate outlet 20, laminate flow path 52, location 50
within housing 12 where primary outlet 34 and secondary outlets 36
and 38 are proximately co-located, etc. It will be apparent to one
skilled in the art that it is desirable to minimize the resistance
to the flow of the extrudates in the one or more flow paths. As
such, further alternate embodiments will become apparent to one
skilled in the art. All such embodiments are considered as being
within the metes and bounds of the instant invention.
[0041] FIGS. 5A-5C illustrate a non-limiting exemplary embodiment
of feedblock 100 having a unitary or a single secondary inlet 102
on a side of feedblock 100 different from the side having primary
inlet 14. FIG. 5A shows secondary inlet 102 in fluid communication
with two secondary flow paths 106 and 106 extending between their
respective secondary outlets and secondary inlet 102. The extrudate
entering secondary inlet 102 is directed into extrudate
distributions blocks 26 and 28 wherein it flows along secondary
flow paths 104 and 106 in the direction indicated by arrows 108 and
110, respectively. As illustrated in FIG. 5B, within extrudate
distribution blocks 26 and 28, the extrudate in secondary flow
paths 104 and 106 flows through flow path sections 112 and 82 in
respective extrudate distribution blocks 26 and 28. The extrudate
exits extrudate distribution blocks 26 and 28 at respective
secondary outlets 36 and 38 and is juxtaposed with the extrudate
entering primary inlet 14 and flowing along primary flow path 40.
The laminate thus formed proximate the location identified by
numeral 50 flows along laminate flow path 52 and exits feedblock
100 at laminate outlet 20.
[0042] In accordance with a non-limiting exemplary embodiment of
the invention, feedblock 100 is configured for enabling or
disabling the flow of the extrudate in secondary flow paths 104 and
106. As illustrated in FIG. 5A, feedblock 100 includes plugs 114
and 116 having respective stems 118 and 120 which at least
partially extend into at least a portion of secondary flow paths
104 and 106. As shown, stems 118 and 120 are "short" and configured
to not hinder or block the flow of extrudate in secondary flow
paths 104 and 106. Accordingly, the flow of extrudate in either one
(or both) secondary flow paths 104 and 106 can be blocked by
placing an obstruction therein. Referring now to FIG. 5C, it is
seen that the flow of extrudate in secondary flow path 106 is
blocked by replacing plug 116 (having short stem 120) with plug 122
having "long" stem 124. It should be apparent that stem 124 of plug
122 must be configured for a snug or tight fit within secondary
flow path 106. While FIG. 5C shows plug 122 obstructing the flow of
the extrudate in secondary flow path 106, it should be readily
apparent that plug 122 can be similarly used for obstructing or
blocking the flow of extrudate in secondary flow path 104, instead
of that in secondary flow path 106. Alternate configurations or
methods for obstructing or blocking the flow of extrudate in
secondary flow paths 104 and 106 will become apparent to one
skilled in the art. All such variants of the described and/or
illustrated embodiments are considered as being within the metes
and bounds of the instant invention.
[0043] Turning now to FIGS. 3 and 4, keyed opening 56 of combining
plane 24 is illustrated as having a substantially circular
cross-section with longitudinally extending groove or slot or
indentation 88 on at least a portion of inside surface 90 of keyed
opening 56. In some embodiments of the invention, groove 88 extends
at least a portion of the longitudinal extent of keyed opening 56.
In other embodiments of the invention, groove 88 extends the entire
longitudinal extent (or length) of keyed opening 56. As previously
described, some embodiments of the invention include an adjustment
mechanism having a shaft or an extension configured for
individually and independently operating the corresponding
combining plane and/or for manipulating the responsiveness of the
corresponding combining plane to the equilibrium pressures exerted
thereon. Accordingly, it will be apparent to one skilled in the art
that at least the outside surface of the shaft of the corresponding
adjustment mechanism 60 should be substantially similar to or match
inside surface 90 of keyed opening 56 within which it is received.
As such, at least a portion of the outside surface of the shaft of
adjustment mechanism 60 will include a mating protrusion matching,
and configured for being received within, groove or slot or
indentation 88 on inside surface 90 of keyed opening 56.
[0044] In view of the foregoing, it will be apparent to one skilled
in the art that at least the cross-sectional geometry or shape of
keyed opening 56 and that of the shaft of adjustment mechanism 60
can be different from that illustrated in FIGS. 3 and 4. For
instance, while keyed opening 56 is illustrated in FIGS. 3 and 4 as
having a substantially circular cross-section, this is not a
requirement. FIGS. 6A-6C illustrate an exemplary embodiment wherein
at least the cross-sectional geometry of keyed opening 94 is
different from that of keyed opening 56. Accordingly, the
cross-sectional geometry of the shaft of adjustment mechanism 98
will be substantially similar to that of keyed opening 94 within
which it is received. Alternate embodiments of and alternatively
shaped keyed openings and the shaft of the corresponding adjustment
mechanisms configured for providing the described operational
functionalities are considered as being within the metes and bounds
of the instant invention.
[0045] While keyed openings 56 and 94 in combining plane 24 are
referenced in the foregoing descriptions, it should be understood
that, in some embodiments of the invention, keyed opening 54 in
combining plane 22 will be substantially similar, both structurally
and functionally, to keyed opening 56 and/or keyed opening 92. In
alternate embodiments of the invention, while combining planes 22
and 24 are structurally and functionally similar, their respective
keyed openings can be different from one another. For instance, in
a non-limiting exemplary embodiment of the invention, combining
plane 22 includes keyed opening 92 (see FIG. 6A) similar to keyed
opening 94 as shown and described with reference to FIGS. 6A-6C
while combining plane 24 includes keyed opening 56. Alternately,
combining plane 22 may include keyed opening 54 while combining
plane 24 includes keyed opening 94. It should be understood that
cross-sectional geometry and/or the outside surface geometry of the
shaft of the adjustment mechanism must substantially match the
keyed opening within which it is received. In view thereof, all
alternate structural and/or functional embodiments for the keyed
openings in the combining planes and the shaft of the adjustment
mechanisms received within those keyed openings, as may become
apparent to one skilled in the art, are considered as being within
the metes and bounds of the instant invention.
[0046] As disclosed and described herein above with reference to
FIGS. 1-4, feedblock 10, in accordance with a non-limiting
exemplary embodiment of the invention, is configured for forming a
laminate having two or more layers of extrudates exiting any two of
primary outlet 34 and secondary outlets 36 and 38.
[0047] A method for forming a laminate, in accordance with a
non-limiting exemplary embodiment of the invention, includes
providing feedblock 10 in accordance with the various embodiments
of the invention, introducing a flow of an extrudate in primary
inlet 14 and in a unitary or single secondary inlet or in each of
the at least two secondary inlets 16 and 18, forming a laminate at
the approximate location identified by reference numeral 50, and
extruding the laminate through laminate outlet 20 in housing 12 of
feedblock 10. As such, the method forms a laminate having a layer
of the extrudate exiting primary outlet 34 juxtaposed between
layers of extrudates exiting each one of secondary outlets 36 and
38.
[0048] As disclosed and described in the foregoing with reference
to FIGS. 1-4, feedblock 10 is configured for effectuating the
thicknesses of the extrudates exiting primary outlet 34 and each
one of secondary outlets 36 and 38. Additionally, feedblock 10 is
also configured for forming a three-layer or a two-layer laminate
and for simply extruding a single layer of an extrudate.
Accordingly, the method includes modulating the mass flow rates of
the extrudates in primary flow path 40 and in each one of secondary
flow paths 42 and 44 for effectuating the thicknesses of the
extrudates exiting primary outlet 34 and each one of secondary
outlets 36 and 38. As such, the thicknesses of each layer of
extrudate forming the laminate can be modulated or set. In
accordance with another embodiment of the invention, each combining
plane 22 and 24 is operated in a free-floating mode responsive to
the equilibrium pressures exerted on each combining plane 22 and 24
by the mass flow rates of the extrudates in primary flow path 40
and in each one of secondary flow paths 42 and 44. In accordance
with yet another embodiment of the invention, the method includes
steps for setting the extent (or sensitivity) of the responsiveness
of combining planes 22 and 24 to the equilibrium pressures exerted
thereon by the mass flow rates of the extrudates in primary flow
path 40 and in each one of secondary flow paths 42 and 44.
Additionally, the method includes steps for setting the thicknesses
of the extrudates exiting primary outlet 34 and each one of
secondary outlets 36 and 38 to pre-determined values. Accordingly,
the method provides for changing, closing and/or opening one or
more of primary outlet 34 and secondary outlets 36 and 38 either by
setting combining planes 22 and 24 to pre-determined fixed
positions or by modulating the mass flow rates of the extrudates in
one or more of primary flow path 40 and secondary flow paths 42 and
44.
[0049] Various modifications and additions may be made to the
exemplary embodiments described hereinabove without departing from
the scope, intent and spirit of the instant invention. For example,
while the disclosed embodiments refer to particular features, the
scope of the instant invention is considered to also include
embodiments having various combinations of features different from
and/or in addition to those described hereinabove. Accordingly, the
present invention embraces all such alternatives, modifications,
and variations as within the scope, intent and spirit of the
appended claims, including all equivalents thereof.
* * * * *